US20220195576A1 - Method of forming an abrasive coating on a fan blade tip - Google Patents
Method of forming an abrasive coating on a fan blade tip Download PDFInfo
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- US20220195576A1 US20220195576A1 US17/687,901 US202217687901A US2022195576A1 US 20220195576 A1 US20220195576 A1 US 20220195576A1 US 202217687901 A US202217687901 A US 202217687901A US 2022195576 A1 US2022195576 A1 US 2022195576A1
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- 239000011248 coating agent Substances 0.000 title claims abstract description 67
- 238000000034 method Methods 0.000 title claims abstract description 44
- 238000000151 deposition Methods 0.000 claims abstract description 37
- 239000002245 particle Substances 0.000 claims abstract description 34
- 230000008021 deposition Effects 0.000 claims abstract description 28
- 239000000758 substrate Substances 0.000 claims abstract description 11
- 239000007921 spray Substances 0.000 claims description 85
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 77
- 229910052782 aluminium Inorganic materials 0.000 claims description 40
- 239000011159 matrix material Substances 0.000 claims description 28
- 238000005507 spraying Methods 0.000 claims description 19
- 239000000843 powder Substances 0.000 claims description 18
- 238000002347 injection Methods 0.000 claims description 15
- 239000007924 injection Substances 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 9
- 239000011521 glass Substances 0.000 claims description 8
- 229910000838 Al alloy Inorganic materials 0.000 claims description 5
- 239000004593 Epoxy Substances 0.000 claims description 4
- 239000010953 base metal Substances 0.000 abstract description 3
- 229910052751 metal Inorganic materials 0.000 description 16
- 239000002184 metal Substances 0.000 description 16
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 238000002485 combustion reaction Methods 0.000 description 4
- 239000007769 metal material Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 2
- HPNSNYBUADCFDR-UHFFFAOYSA-N chromafenozide Chemical compound CC1=CC(C)=CC(C(=O)N(NC(=O)C=2C(=C3CCCOC3=CC=2)C)C(C)(C)C)=C1 HPNSNYBUADCFDR-UHFFFAOYSA-N 0.000 description 2
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/123—Spraying molten metal
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
- F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
- F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
- F01D11/122—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with erodable or abradable material
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/288—Protective coatings for blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
- F05D2230/31—Layer deposition
- F05D2230/312—Layer deposition by plasma spraying
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
- F05D2300/12—Light metals
- F05D2300/121—Aluminium
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- General Engineering & Computer Science (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Structures Of Non-Positive Displacement Pumps (AREA)
Abstract
Description
- This application is a continuation of U.S. application Ser. No. 14/705,165 filed May 6, 2015, the disclosure of which is incorporated herein by reference in its entirety.
- The subject matter of the present disclosure relates generally to a method of finishing a rotating turbomachine component such as a fan blade. More particularly, the subject matter relates to a method of forming an abrasive coating on a fan blade tip of the type used in gas turbine engines.
- Gas turbine engines, such as those used on jet aircraft, generally comprise an air intake port, a fan section, a low pressure compressor (LPC) section, an intermediate section aft of the LPC section, a high pressure compressor (HPC) section, a combustion chamber or combustor, high and low pressure turbines that provide rotational power to the compressor blades and fan respectively, and an exhaust outlet. The fan and LPC section may be operably connected to the low pressure turbine by an inner drive shaft which rotates about an engine center axis. A cone-like spinner may be mounted over the hub forward the fan blades to help guide air flow.
- The fan section generally comprises fan blades mounted to a hub and enclosed within a fan case assembly. The fan case assembly generally comprises a fan containment case and an abradable liner (a.k.a. outer air seal) disposed within the fan containment case. The clearance between the fan blade tips and the abradable liner is generally kept to a minimum for maximum engine efficiency.
- One practice used in the aerospace industry to optimize the clearance between the fan blade tips and the abradable liner is to apply an abrasive coating on the fan blade tips, then operate the fan until the abrasive coating rubs off a desired amount of the abradable liner.
- Examples of coatings for abradable liners can be found in U.S. Pat. Nos. 3,575,427, 6,334,617, and 8,020,875. One exemplary baseline coating comprises a silicone matrix with glass micro-balloon filler. Without the glass micro-balloon filler, the elastic properties of the abradable coating results in vibrational resonances and non-uniform rub response. The glass micro-balloons increase the effective modulus of the coating so as to reduce deformation associated with aerodynamic forces and resonances. More recent proposals include fillers such as polymer micro-balloons (PCT/US2013/023570) and carbon nanotubes (PCT/US2013/023566).
- For interfacing with the abradable liner, the fan blade tips may bear an abrasive coating. US Patent Application Publication 2013/0004328 A1, published Jan. 3, 2013, and entitled “Abrasive Airfoil Tip” discloses a number of such coatings.
- The present disclosure is directed to forming an abrasive coating on a fan blade tip. Among other benefits, the method reduces heat generation when the fan blade tip rubs against the abradable liner.
- A novel method of forming an abrasive coating on a surface of a rotating turbomachine component such as a fan blade tip is provided. The fan blade comprises an airfoil section and a tip. The airfoil section has a metallic substrate such as aluminum. The fan blade is mounted to a hub and is configured to rotate within a fan case assembly. The fan case assembly comprises an abradable liner made of an abradable material.
- The method enhances grit capture by presenting a softened coating surface for the impinging grit particles. The softened surface is achieved without high substrate temperatures that could degrade the base metal properties in the fan blade. An auxiliary heat source is used to establish a locally heated and softened surface where the grit deposition takes place. The softened surface greatly increases the probability of grit capture.
- In one aspect, the method comprises the steps of providing a feedstock of aluminum powder; heating the aluminum powder until the aluminum powder is molten; spraying the molten aluminum powder onto a spray plume area of the fan blade tip with a plasma spray gun to form a coating; and depositing grit particles onto the coating while maintaining the temperature of the coating within a desired range by controlling deposition rate parameters.
- The deposition rate parameters include aluminum powder feed rate, traverse rate of the plasma spray gun and the spray plume area.
- The aluminum powder feed rate may be between about 20 g/min and 120 g/min, and preferably between about 30 g/min and 60 g/min.
- The traverse rate of the plasma spray gun may be between about 1200 inches per minute and about 20 inches per minute, and preferably between about 900 inches per minute and about 500 inches per minute.
- The aluminum powder may be heated by introducing the powder into a plasma plume emanating from a plasma spray gun.
- Before the depositing step the grit particles may be introduced into a plasma jet stream downstream from the plasma plume so the grit particles do not melt.
- The grit particles should be harder than the abradable material in the abradable liner, which may be glass micro-balloons.
- The airfoil section of the fan blade may comprise a metal-based material such as aluminum or an aluminum alloy.
- In another aspect of the disclosure the traverse rate of the plasma spray gun may be varied during the spraying step.
- In another aspect the plasma spray gun is directed along a spray path. The spray path may be varied to increase spray path spacing or to increase or decrease spray overlap.
- In another aspect the plasma spray gun has an axis of rotation and an axis of powder injection substantially perpendicular to the axis of rotation of the spray gun and, during the spraying step, the plasma spray gun is rotated about its axis of rotation. The plasma spray gun may be oriented with its axis of powder injection substantially parallel to the traverse direction (to minimize spray plume width) or in any other orientation with respect to the traverse direction, and may change during spraying.
- So that the manner in which the concepts of the present disclosure recited herein may be understood in detail, a more detailed description is provided with reference to the embodiments illustrated in the accompanying drawings. It is to be noted, however, that the accompanying drawings illustrate only certain embodiments and are therefore not to be considered limiting of the scope of the disclosure, for the concepts of the present disclosure may admit to other equally effective embodiments. Moreover, the drawings are not necessarily to scale, emphasis generally being placed upon illustrating the principles of certain embodiments.
- Thus, for further understanding of these concepts and embodiments, reference may be made to the following detailed description, read in connection with the drawings in which:
-
FIG. 1 is a partial side cross-sectional view of an exemplary gas turbine engine. -
FIG. 2 is a perspective view of the fan section of a gas turbine engine, including a fan case assembly and fan blades. -
FIG. 3 is a cross-sectional view of the fan section ofFIG. 2 taken along line 3-3 and showing a partial fan blade and a portion of theabradable liner 34. -
FIG. 4 is a close up view of a fan blade tip and abrasive tip coating according to the disclosure. -
FIG. 5 is a schematic of a method of finishing a fan blade according to the disclosure. - In the disclosure that follows certain relative positional terms may be used such as “forward”, “aft”, “upper”, “lower”, “above”, “below”, “inner”, “outer” and the like. These terms are used with reference to the normal operational attitude of a jet engine and should not be considered otherwise limiting. The forward end of a jet engine generally refers to the air intake port end and the aft end generally refers to the exhaust end. Also, “radially outward” generally refers to a direction away from the engine center axis while “radially inward” refers to a direction toward the engine center axis. Finally, although the following disclosure relates to a method of forming an abrasive coating on a fan blade tip, it should be understood that the method may be used with other components.
- Turning to the figures,
FIG. 1 is a longitudinal partial cross-sectional view of an exemplarygas turbine engine 10. Thegas turbine engine 10 comprises anair inlet 12, afan section 14, a single ormulti-stage compressor section 16, acombustion section 18 downstream of thecompressor section 16, a single ormulti-stage turbine section 20, and anexhaust nozzle 22. Air entering theair inlet 12 flows through thecompressor section 16 and into thecombustion section 18 where it provides oxygen for fuel combustion. The hot combustion gases pass through theturbine section 20 and exit theexhaust nozzle 22, providing a portion of the engine's thrust. -
FIG. 2 is a perspective view of afan section 14 as may be found in a typicalgas turbine engine 10. Thefan section 14 generally comprises a plurality of circumferentially-spacedfan blades 24 mounted to ahub 26 and enclosed within afan case assembly 28. Thefan case assembly 28 may comprise a thermally conformingliner 32 disposed within afan containment case 30. Thefan containment case 30 is annular in shape and circumscribes thefan blades 24. - The
fan section 14 is designed such that the tolerance between thefan blades 24 and thefan containment case 30 is extremely small. To achieve this tolerance, the fan may be initially operated so that thefan blades 24 rub against thefan containment case 30, as explained in more detail with respect toFIG. 3 . -
FIG. 3 is a cross-sectional view of thefan case assembly 28 ofFIG. 2 , taken along line 3-3 and showing apartial fan blade 24 and a portion of theabradable liner 34. A portion of the thermally conformingliner 32 disposed axially outward from thefan blades 24 is covered with anabradable liner 34 circumferentially mounted on a radiallyinner surface 33 of the thermally conformingliner 32. Theabradable liner 34 may comprise an abradable rub material or coating and has aninboard surface 36 in close proximity to thefan blade tips 25. - The
abradable liner 34 may be formed of or coated with a polymeric based material, such as a polymer matrix composite. The polymeric based material may include an epoxy matrix and a silica-containing filler dispersed through the matrix. In a further example, the abradable material may comprise a silica-containing filler that includes hollow glass micro-balloons, a.k.a. micro-bubbles or micro-spheres. - The
fan blade 24 includes anairfoil section 38 that extends between aleading edge 40 and a trailingedge 42 and between a base 44 (FIG. 2 ) and afree tip 25. Thefan blade tip 25 is covered with anabrasive coating 46, the purpose of which is described below. - The
airfoil section 38 of thefan blade 24 may be formed of a metal-based material and may have a polymeric overcoat on its exterior surface to protect theairfoil section 38 from damage due to foreign particulates ingested into theengine 10. In one example, the metal-based material of theairfoil section 38 is aluminum or an aluminum alloy. The polymeric coating can be a polyurethane-based coating, an epoxy-based coating, or a silicone rubber-based coating, but is not limited to these types of polymeric coatings or materials. - When two components, such as a
fan blade tip 25 and anabradable liner 34, are in rubbing contact, at least one of the components may wear. The term “abradable” refers to the component that wears, while the other component is “abrasive” and does not wear or wears less. The word “abrasive” also implies that there is or can be contact with an abradable component. Thus, when theabrasive tips 25 of thefan blades 24 rub against theabradable liner 34, theabradable liner 34 will be worn, whereas theabrasive tips 25 will not wear or will wear less than theabradable liner 34. - Friction between the
fan blade tip 25 and theabradable liner 34 generates heat. The heat can be conducted into thefan containment case 30, into thefan blade 24, or both. However, in particular formetal fan blades 24 and polymeric-basedfan containment cases 30, the metal of thefan blade 24 is generally a better thermal conductor than the polymer of thefan containment case 30, and a majority of the heat thus is conducted into thefan blade 24. While this may normally not present any problems for a plainmetal fan blade 24, the heat conduction can be detrimental to ametal fan blade 24 that has a polymeric overcoat because the heat can cause delamination of the polymeric overcoat and thus compromise the damage protection. -
FIG. 4 is a close up view of afan blade tip 25 according to the disclosure. Thefan blade tip 25 is covered with anabrasive coating 46 comprising ametal matrix coating 48 andhard particles 50 deposited on or in themetal matrix coating 48. Themetal matrix coating 48 and the metal-based material of thefan blade 24 may be compositionally composed of the same predominant metal, such as aluminum, which can promote strong adhesion between theabrasive coating 46 and thefan blade 24. -
FIG. 5 is a schematic of a method of finishing afan blade 24 according to the disclosure. The method may comprise the following steps: - Providing a feedstock of aluminum powder.
- Heating the aluminum powder until the aluminum powder is molten. The aluminum powder may be introduced into a plasma plume emanating from a plasma spray gun (a.k.a. plasma spray torch), resulting in an electrically heated gas jet stream. The heat energy from the plasma spray gun is transferred to the aluminum powder particles, converting them into molten aluminum droplets. The molten droplets are then propelled toward the
fan blade tip 25 by the gas jet stream. - Spraying the molten aluminum droplets onto an area of the
fan blade tip 25 to form analuminum matrix coating 48. When the molten aluminum droplets hit the surface of thefan blade tip 25 they spread out and cool rapidly due to conductive heat transfer, mainly into themetallic fan blade 24. At this point the droplets may be referred to as “splats.” Spraying can be done via a plasma spray gun. - Depositing
grit particles 50 onto thealuminum matrix coating 48 via a plasma jet stream or other means, while maintaining the temperature of thealuminum matrix coating 48 by controlling certain deposition rate parameters as explained below. - The
grit particles 50 may be introduced into the plasma jet stream downstream from the plasma plume where the temperature of the plasma jet stream is lower. Thegrit particles 50 do not melt but remain angular in shape. Thus, if a sharp corner of agrit particle 50 hits the surface of thealuminum matrix coating 48 first, the sharp corner may create an indent into the still-softaluminum matrix coating 48, and stick there via mechanical embedding. Preferably thegrit particles 50 are harder than the abradable material in theabradable liner 34, which as noted above can be glass micro-balloons. - The likelihood that any
grit particle 50 sticks to thealuminum matrix coating 48 is a function of certain “deposition rate parameters”. The deposition rate parameters may include the velocity of thegrit particle 50, the size and shape of thegrit particle 50, the orientation with which thegrit particle 50 impacts thealuminum matrix coating 48, the temperature of thegrit particles 50, and the “softness” and “stickiness” of thealuminum matrix coating 48, as well as the aluminum powder feed rate, traverse rate of the plasma spray gun and spray plume area. - Accordingly, during the deposition step, certain deposition rate parameters are controlled to optimize or otherwise control grit particle deposition. For example, the surface of the
aluminum matrix coating 48 can be intentionally made hotter to make it softer and stickier, i.e., having a higher tendency to capture thegrit particles 50. - Passive control of the deposition spot temperature can be achieved through control of the deposition rate parameters. For example, the deposition spot temperature is generally directly proportional to the aluminum powder feed rate and the molten aluminum temperature, and inversely proportional to the spray plume area and traverse rate of the plasma spray gun.
- Because aluminum is so heat conductive, there exists a high thermal gradient between the hot
aluminum matrix coating 48 and thealuminum fan blade 24. As a consequence, heat is quickly conducted away from thealuminum matrix coating 48, which helps keep the temperature of thealuminum fan blade 24 in the vicinity of thealuminum matrix coating 48 below an acceptable limit, thus protecting the mechanical properties of thefan blade 24. To counteract this phenomena, and to optimize the surface temperature of thealuminum matrix coating 48 where thegrit particles 50 are being deposited, at least three deposition rate parameters may be controlled: aluminum powder feed rate, traverse rate of the plasma spray gun, and the area of the spray plume on thefan blade tip 25. - Aluminum powder feed rate. “Aluminum droplet flux” is the rate of aluminum droplet deposition per given area of the
fan blade tip 25, and may be expressed in units of grams/minute/area, where the area is determined by the plume width times the distance traversed by the plasma spray gun. Increasing the aluminum droplet flux by impinging more hot aluminum droplets on an area of thefan blade tip 25 over a given period of time generally helps maintain the temperature of thealuminum matrix coating 48 at an acceptably high level. But adding too much aluminum powder to the plasma jet stream can result in poor heating (and melting) of the aluminum powder. The aluminum powder feed rate may be controlled to stay in an operable range of between about 20 g/min and 120 g/min. More preferably, the aluminum powder feed rate is between about 30 g/min and 60 g/min. - Traverse rate of the plasma spray gun. Traverse rate is the rate of linear travel of the plasma spray gun across the surface of the
fan blade tip 25, and may be expressed in units of distance/time. Increasing the traverse rate by moving the plasma spray gun (or other thermal spray means) across the surface of thefan blade tip 25 more quickly results in a lower deposition of aluminum droplets per area, where area is calculated as the traverse rate times the spray plume width. The traverse rate of the plasma spray gun may be between about 1200 inches per minute and about 20 inches per minute. More preferably, the traverse rate of the plasma spray gun is between about 900 inches per minute and about 500 inches per minute. The plasma spray gun power may be 39 kilowatts (kW) or higher. Too much power or a too slow traverse rate can melt the aluminum substrate of thefan blade tip 25. - Spray plume area. As noted above, spray plume area is determined by the spray plume width and the distance traversed by the plasma spray gun. Heat flux is a measure of the rate of energy (heat) transfer through a surface per unit area. In this application heat flux is a measure of the rate of heat transfer from the molten aluminum droplets through the surface of the
fan blade tip 25 for a given spray plume area. Increasing the heat flux increases the temperature of the surface of thefan blade tip 25 which increases the grit deposition efficiency. Increasing the spray plume area on thefan blade tip 25 causes the heat flux to decrease, an undesirable effect. Therefore it is preferred that the spray plume is kept more concentrated (by decreasing the spray plume width as it traverses the fan blade tip 25) for the same number of aluminum droplets, resulting in a higher heat flux. - Once the
abrasive coating 46 is formed on thefan blade tip 25, thefan blades 24 are placed within afan containment case 30 having anabradable liner 34. The fan is then operated so that the abrasivefan blade tips 25 wear out a portion of theabradable liner 34, creating an ideal tolerance (spacing) between thefan blades 24 and theliner 34. - As noted above, the
abradable liner 34 may comprise epoxy bonded glass micro-balloons. If a smooth (“bare metal”) fan blade tip is rubbed against such anabradable liner 34, the temperature can increase to 700 F or more due to frictional heating. Applying an abrasive to thefan blade tip 25 theharder grit particles 50 cut into the micro-balloons, resulting in high local pressures but lower, and better, temperatures. - The method described herein has been shown to result in a deposition efficiency of about 45% (measured as the percentage of
grit particles 50 that stick to the metal matrix coating 48) compared to about 5.6% in baseline methods. This increase in deposition efficiency results in an increase in grit concentration in theabrasive coating 46, and higher wear resistance in service. - There has been described a novel method of depositing
grit particles 50 onto ametal matrix coating 48 that enhances grit capture by presenting a softened coating surface for the impinginggrit particles 50. The softened surface is achieved without causing the temperature of the substrate (i.e., thefan blade 24 in the vicinity of the metal matrix coating 48) to exceed an acceptable temperature that could degrade the aluminum base metal properties in thefan blade 24. An auxiliary heat source such as a laser or the heat of the spray process itself may be used to establish a locally heated and softened metal matrix coating surface where the grit deposition is taking place. The softened surface greatly increases the probability of grit capture. - The use of an auxiliary heat source for localized heating of the
metal matric coating 48 also provides localized temperature control (of the metal matrix coating 48) better than that which can be achieved using practical (conventional) spray parameters. The use of an auxiliary heat source for localized heating of themetal matric coating 48 also allows the control of deposition rate parameters to levels chosen for considerations other than grit capture. The method may also be used to vary grit concentration locally by changing certain deposition rate parameters. - For example, local grit concentration can be locally controlled through relative torch to part motions. The simplest method to accomplish this control is to vary the traverse rate over the part to achieve a higher surface temperature and higher resultant grit concentration in an area where traverse is relatively slower. However, this method results in relatively thicker coating in the area of reduced traverse speed. This may be overcome by locally reducing the number of time the torch traverses over the area or by concurrently varying spray path spacing and related spray stripe overlap. Alternatively, rotational orientation of the spray torch about its axis may be used to adjust the width of the spray plume. This is achieved by taking advantage of the typically asymmetric powder and droplet distribution caused by substantially radial powder injection. By rotating the torch to position the powder injection parallel to the traverse direction, the spray plume has its minimum width, when it is perpendicular to the traverse direction, the spray plume is at its maximum width. Thus, by changing the rotational orientation of the spray torch about its axis, particle flux may be adjusted to achieve the desired local control of abrasive grit concentration in the coating.
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US10072506B2 (en) * | 2014-06-30 | 2018-09-11 | Rolls-Royce Corporation | Coated gas turbine engine components |
US11268183B2 (en) * | 2015-05-06 | 2022-03-08 | Raytheon Technologies Corporation | Method of forming an abrasive coating on a fan blade tip |
US10526908B2 (en) | 2017-04-25 | 2020-01-07 | United Technologies Corporation | Abradable layer with glass microballoons |
CN114055805B (en) * | 2020-08-10 | 2023-09-08 | 中国航发商用航空发动机有限责任公司 | Manufacturing method of easy-to-wear ring of aero-engine fan |
CN114382725A (en) * | 2020-10-19 | 2022-04-22 | 宏达国际电子股份有限公司 | Fan blade and manufacturing method thereof |
FR3122595B1 (en) * | 2021-05-05 | 2024-04-26 | Safran Helicopter Engines | Process for manufacturing a turbine blade for a turbomachine |
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US11920245B2 (en) | 2024-03-05 |
US11268183B2 (en) | 2022-03-08 |
EP3091099B1 (en) | 2019-07-03 |
US20160326622A1 (en) | 2016-11-10 |
EP3091099A1 (en) | 2016-11-09 |
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